FRP Fabrication Manual

One of the Leading Company for FRP PIPE & FITTINGS
Engineering & Manufacturing in the World
FABRICATION MANUAL
for
FRP PIPE & FITTINGS

.
BOSUNG ENGINEERING & MANUFACTURING Co.Ltd.

www.bosungem.com
TEL:+82-32-441-8881 FAX:82-32-442-8886
BOSUNG E.& M. STANDARD
PAGE
2 / 26
0
Standard No.
BCP-P-09
Revise No.
Standard
Name
F.R.P. Piping
Fabrication Manual
Date
1.0 Introduction
1.1
This fabrication manual shall apply to the fabrication of F.R.P (Glassfiber

Reinforced Polyester) Piping.
1.2
Glass Fiber Mat shall be kept under the humidity-free condition.
1.3
Containers for materials curing shall be made from stainless steel, P.V.C,
P.E, or F.R.P..
2.0 Application Code

Inner Chemical protective Resistance Layer/Outer
U.V. Protection Layer
Pipes
1
2
NBS PS 15-69
Fittings
Structure layer
ASTM D2996
Chemical Protective Resistance Layer + Structure
ASTM D5685
layer + U.V. Protection Layer

3
Flanges
Chemical Protective Resistance Layer + Structure
ASTM D5421
layer + U.V. Protection Layer
3.0 Materials
3.1
Isophthalic Polyester Resin shall be used for resin.
3.2
Fillers, Accelerators or Catalysts

3.2.1 Users shall not add to fillers to enhance painting or for the control
of viscosity.
3.2.2
Before using accelerators or catalysts, users must take curing into

consideration and if these are used, users must mention it in the
fabrication standards.
BSS-0202-A
BOSUNG ENG. &MFG. CO., LTD.
A4(210X297)
3.3
PAGE
3 / 26
0
Standard No.
BCP-P-09
Revise No.
Standard
Name
F.R.P. Piping
Fabrication Manual
Date
Reinforcing Materials
Users must adopt surface-treated reinforcing materials to improve adhesive
strength with resins and reinforcing materials consist of the followings. :
-. Inner Surface Layer (Surface Corrosion Resistance Layer) Chemical Surfacing Mat, Type "C" Glass
-. Interior Layer (Interior Corrosion Resistance Layer) Electrical Chopped Strand Mat, Type "E" Glass
-. Reinforcing Layer(Exterior Layer)) -. Exterior Surface -
YARN Type "E" Glass
Top Coating (Including Ultraviolet Inhibitor)
4.0 Fabrication
4.1
Structure Layers
4.1.1
Inner Surface Layer
1)
Isophthalic Polyester Resin shall be used for this layer.
2)
Inner Surface shall be free of cracks and crazing.
3)
As for Inner Surface, Chemical Surfacing Mat Type "C" Glass must be
overlapped with a width of minimum 2 inch.
4)
Between 0.01 inch and 0.02 inch of reinforced resin-rich surface

shall be provided.
5)
Inner
Surface must avoid exposure of inner surface fabric.
6)
Finish Surface must be smooth and have an average of not over 2 pits
per square foot, providing the pits are less than 0.12inch in diameter
and not over 0.02inch deep.
4.1.2
Interior Layer
1) Isophthalic Polyester Resin must be used for this layer.
BSS-0202-A
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name
F.R.P. Piping Fabrication

Manual
Date
2)
Inner surface shall be reinforced with not less than 20% nor more
than 30% of Electrical Chopped Strand Mat Type "E" Glass.
4.1.3
Reinforcing Layer
1)
Vinylester Polyester Resin shall be used for this layer.
2)
Reinforcing Layer shall be lapped with Type "E" Glass YARN.
3)
Pipe wall thickness can be controled by Reinforcing Layer.
4)
In the first lapping of resin, the layer shall be lapped less than
0.2inch absolutely.
Considering air bubbles, the layer shall be
lapped up to 0.12 ~ 0.16inch thickness and then cured.

After the curing heat is cooled the second and third lapping of
resin must be done up to the required thickness.
4.1.4
Exterior Surface
1)
Exterior Surface shall be lapped by the sufficient resin which

contains Ultraviolet Inhibitor.
2)
Considering the outer corrosive environment, the resin used for

Exterior Surface must be able to resist those environments.
4.2
Cut Edges
4.2.1
All cut edges shall be coated with resin so that no glass fiber are
exposed and all voids filled.
4.2.2
Structural elements having cut edges exposed to the chemical
environment
shall be made from only Glass Chopped-Strand Mat.
4.3
Connecting
4.3.1
F.R.P pipe connecting must be conducted by Butt Joint or Flange Joint.
4.3.2
In principle, connecting pipe to pipe shall be done by Butt Joint.
4.3.3
Flange Joint can apply to valve, vessel nozzle and outlet (Cleanout).
BSS-0202-A
A4(210X297)
4.3.4
PAGE
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
Butt Joint shall be applied in accordance with the followings :

1)
The joint finish must be a successive layers' structure and the

jointed part shall be at least equal to the strength of the
corresponding part.
2)
There must not be any gap between the jointed part and the
corresponding part when lapping.
3)
The width of the first layer shall be a minimum of 2inch.
4)
Successive layers shall increase uniformly to provide the specified

minimum total width of overlay which meet the width of the lst
layer.(Refer to the following table.)
F.R.P. Piping Butt Joint
Pipe Diameter(mm)
Over Lay TH'K(mm)
Outer Minimum Width(mm)
15
80
25
80
40
80
50
80
65
80
80
80
100
80
125
80
150
80
200
91
250
102
300
114
350
134
400
152
450
172
600
229
750
286
800
305
850
324
900
343
1100
419
BSS-0202-A
Remark
A4(210X297)
4.4
PAGE
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
Pipe Wall Thickness

4.4.1
F.R.P Standard Pipe wall thickness shall be in accordance with maker's

design condition.
4.4.2
Isolated small spots of pipe may be as thin as 87.5% of the minimum

required wall thickness.
4.5
Fittings
4.5.1
All fittings shall be the same as corresponding pipes in strength,

materials' thickness and diameter.
4.6
Flange
4.6.1
The diameter and drilling template of flange 24inch and smaller shall be
in accordance with ASME/ANSI B16.5 150#, for 26inch and large to
ASME/ANSI B16.47 150# series A.
4.6.2
The face of the flange attachment shall be flat faced flange.
4.6.3
The thickness of the flange hub shall be at least one-half times as the
thickness of flange.
4.6.4
The perpendicular allowance of flange face shall be less than 1/2to

the axis of the pipe.
4.6.5
The flange face shall be perpendicular to the axis of the pipe and flat
to 0.032inch up to 18inch diameter and 0.064inch for larger
diameters.
4.6.6
The face of flange shall keep the chemical protective and abrasion
resistant property.
4.6.7
BSS-0202-A
The side of bolt hole at the back of the flange must be flat enough to
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
PIPE DIMENSION TABLE
N.S(A)
I.D
15
12.7
25
25.4
40
38.1
50
50.8
65
63.5
80
76.2
100
101.6
125
127
150
152.4
200
203.2
250
254.0
300
304.8
355.6
400
406.4
450
457.2
600
600.0
750
750.0
BSS-0202-A
REMARK
A4(210X297)
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S(A)
I.D
800
800.0
850
850.0
900
900.0
1100
1100.0
BSS-0202-A
PAGE
REMARK
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
ELBOW (90 & 45) DIMENSION TABLE
N.S(A)
I.D
15
12.7
105
44
25
25.4
105
44
40
38.1
105
44
50
50.8
105
44
65
63.5
105
44
80
76.2
120
50
100
101.6
150
62
125
127
188
78
150
152.4
225
93
200
203.2
300
124
250
254
375
155
300
304.8
450
186
BSS-0202-A
REMARK
Fitting thickness
is equal to the
pipe thickness.
A4(210X297)
10 / 26
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S(A)
I.D
350
355.6
525
218
400
406.4
600
249
450
457.2
675
280
600
600.0
900
373
750
750.0
1125
466
800
800.0
1200
497
850
850.0
1275
528
900
900.0
1350
559
1100
1100.0
1650
684
BSS-0202-A
PAGE
REMARK
Fitting thickness
is equal to the
pipe thickness.
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
TEE DIMENSION TABLE
N.S 1 (mm)
N.S 2 (mm)
15 x
15
20 x
L1 (mm)
L2 (mm)
REMARK
15
20
15
25 x
20
25
15
20
32 x
150
25
32
150
Fitting
Thickness
is equal to the
pipe thickness.
15
20
40 x
25
32
40
BSS-0202-A
A4(210X297)
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
50 x
65 x
80 x
100 x
125 x
150 x
200 x
BSS-0202-A
N.S 2 (mm)
15
20
25
32
40
50
25
32
40
50
65
32
40
50
65
80
40
50
65
80
100
50
65
80
100
125
65
80
125
150
100
125
150
100
125
150
200
L1 (mm)
L2 (mm)
150
150
200
200
250
260
275
300
350
360
375
400
REMARK
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
250 x
300 x
350 x
400 x
450 x
500 x
550 x
BSS-0202-A
N.S 2 (mm)
L1 (mm)
L2 (mm)
REMARK
100
125
150
200
250
125
150
200
250
300
150
200
250
300
350
150
200
250
300
350
400
200
250
300
350
400
450
200
250
300
350
400
450
500
250
300
350
400
450
500
550
275
290
300
325
350
310
325
350
375
400
350
375
400
425
450
375
400
425
450
475
500
425
450
475
500
524
550
450
475
500
525
550
575
600
500
525
550
575
600
625
650
375
390
400
425
450
410
425
450
475
500
450
475
500
525
550
475
500
525
550
575
600
525
550
575
600
624
650
550
575
600
625
650
675
700
600
625
650
675
700
725
750
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
N.S 1 (mm)
600 x
650 x
700 x
750 x
800 x
BSS-0202-A
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 2 (mm)
L1 (mm)
L2 (mm)
REMARK
250
300
350
400
450
500
550
600
300
350
400
450
500
550
600
650
300
350
400
450
500
550
600
650
700
300
350
400
450
500
550
600
650
700
750
350
400
450
500
550
600
525
550
575
600
625
650
675
700
575
600
625
650
675
700
725
750
600
625
650
675
700
725
750
775
800
625
650
675
700
725
750
775
800
825
850
675
700
725
750
775
800
375
390
400
425
450
410
425
450
475
500
450
475
500
525
550
475
500
525
550
575
600
525
550
575
600
624
650
550
575
600
625
650
675
700
600
625
650
675
700
725
750
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
N.S 1 (mm)
800 x
850 x
900 x
950 x
1000 x
BSS-0202-A
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 2 (mm)
650
700
750
800
400
450
500
550
600
650
700
750
800
850
400
450
500
550
600
650
700
750
800
850
900
450
500
550
650
700
750
800
850
900
950
450
500
550
600
650
700
L1 (mm)
825
850
875
900
725
750
775
800
825
850
875
900
925
950
750
775
800
825
850
875
900
925
950
975
1000
800
825
850
900
925
950
975
1000
1025
1050
825
850
875
900
925
950
L2 (mm)
REMARK
925
950
975
1000
825
850
875
900
925
950
975
1000
1025
1050
850
875
900
925
950
975
1000
1025
1050
1075
1100
900
925
950
1000
1025
1050
1075
1100
1125
1150
925
950
975
1000
1025
1050
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
1000 x
1050 x
1100 x
1150 x
BSS-0202-A
N.S 2 (mm)
L1 (mm)
L2 (mm)
REMARK
750
800
850
900
950
1000
450
500
550
600
650
700
750
800
850
900
950
1000
1050
500
550
600
650
700
750
800
850
900
1000
1050
1100
550
600
650
700
800
850
900
950
1000
1050
975
1000
1025
1050
1075
1100
850
875
900
925
950
975
1000
1025
1050
1075
1100
1125
1150
900
925
950
975
1000
1025
1050
1075
1100
1150
1175
1200
950
975
1000
1025
1075
1100
1125
1150
1175
1200
1075
1100
1125
1150
1175
1200
950
975
1000
1025
1050
1075
1100
1125
1150
1175
1200
1225
1250
1000
1025
1050
1075
1100
1125
1150
1175
1200
1250
1275
1300
1050
1075
1100
1125
1175
1200
1225
1250
1275
1300
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
PAGE
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Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
1150 x
1200 x
BSS-0202-A
N.S 2 (mm)
L1 (mm)
L2 (mm)
REMARK
1100
1150
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1225
1250
975
1000
1025
1050
1075
1100
1125
1150
1175
1200
1225
1250
1275
1300
1325
1350
1075
1100
1125
1150
1175
1200
1225
1250
1275
1300
1325
1350
1375
1400
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
REDUCER DIMENSION TABLE
N.S 1 (mm)
N.S 2 (mm)
L1 (mm)
20 x
20
50
15
50
20
50
15
50
20
50
25
50
15
65
20
50
25
50
32
50
15
90
20
75
25
65
32
50
40
50
25 x
32 x
40 x
50 x
BSS-0202-A
REMARK
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
N.S 1 (mm)
60 x
80 x
100 x
125 x
150x
200 x
250 x
300 x
350 x
BSS-0202-A
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Standard No.
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Revise No.
Standard Name

Manual
Date
N.S 2 (mm)
L1 (mm)
25
32
40
50
32
40
50
65
40
50
65
80
50
65
80
100
65
80
100
125
80
100
125
150
100
125
150
200
125
150
200
250
150
200
250
300
100
85
65
50
120
100
75
40
150
125
90
50
190
150
115
65
215
175
125
65
300
250
190
125
375
315
250
125
440
375
250
125
500
375
250
125
REMARK
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
N.S 1 (mm)
400x
450 x
500 x
550 x
600 x
650 x
700 x
750 x
PAGE
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Standard No.
BCP-P-09
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Standard Name

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Date
N.S 2 (mm)
L1 (mm)
200
500
250
300
375
250
350
250
300
125
500
350
250
400
125
300
500
350
375
400
250
450
125
350
500
400
375
450
250
500
125
400
500
450
375
500
250
550
125
450
500
500
375
550
250
600
125
450
625
500
500
550
375
600
250
650
125
500
625
550
500
600
375
650
250
700
125
REMARK
375
Fitting
Thickness
is equal to the
pipe thickness.
BSS-0202-A
A4(210X297)
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Standard No.
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Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
800x
850 x
900 x
950 x
1000 x
1050 x
BSS-0202-A
N.S 2 (mm)
L1 (mm)
600
500
650
700
375
250
750
600
650
125
625
700
375
750
250
800
125
600
750
650
625
700
500
750
375
800
250
850
125
650
750
700
625
750
500
800
375
850
250
900
125
750
625
800
500
850
375
900
250
950
125
750
750
800
625
850
500
900
375
950
250
1000
125
REMARK
500
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S 1 (mm)
1100x
1150 x
1200 x
BSS-0202-A
N.S 2 (mm)
L1 (mm)
850
625
900
950
500
375
1000
250
1050
125
950
500
1000
375
1050
250
1100
125
1000
500
1050
375
1100
250
1150
125
REMARK
Fitting
Thickness
is equal to the
pipe thickness.
A4(210X297)
PAGE
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
FLANGE DIMENSION TABLE
ANSI 150#
N.S(A)
I.D
O.D
BCD
N-
15
12.7
89
60.5
17.5
150
4-16
25
25.4
108
79.2
17.5
150
4-16
40
38.1
127
98.6
17.5
150
4-16
50
50.8
152
120.7
19.1
150
4-19
65
63.5
178
139.7
19.1
150
4-19
80
76.2
191
152.4
22.2
150
4-19
100
101.6
229
191
25.4
150
8-19
125
127
254
216
28.6
200
8-22
150
152.4
279
241.3
28.6
200
8-22
200
203.2
343
298.5
33.4
200
8-22
BSS-0202-A
REMARK
A4(210X297)
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0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S(A)
I.D
O.D
BCD
N-
250
254
406
362
38.1
200
12-25
300
304.8
483
431.8
47.6
200
12-25
350
355.6
533
476.3
50.8
300
12-28
400
406.4
597
539.8
57.2
300
16-28
450
457.2
635
577.9
57.2
300
16-32
600
600
813
749.3
69.9
300
20-35
750
750
984
914.4
79.4
380
28-35
800
800
1061
977.9
88.9
380
28-41
850
850
1111
1028.7
88.9
380
32-41
900
900
1168
1085.9
88.9
380
32-41
1100
1100
1403
1314.5
117.5
380
40-41
BSS-0202-A
REMARK
ASME/ANSI
B16.47, 150#
Series A.
A4(210X297)
PAGE
25 / 26
0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
BLIND FLANGE DIMENSION TABLE
ANSI 150#
N.S(A)
O.D
BCD
N-
15
89
60.5
17.5
4-16
25
108
79.2
17.5
4-16
40
127
98.6
17.5
4-16
50
152
120.7
19.1
4-19
65
178
139.7
19.1
4-19
80
191
152.4
22.2
4-19
100
229
191
25.4
8-19
125
254
216
28.6
8-22
150
279
241.3
28.6
8-22
200
343
298.5
33.4
8-22
BSS-0202-A
REMARK
A4(210X297)
PAGE
26 / 26
0
Standard No.
BCP-P-09
Revise No.
Standard Name

Manual
Date
N.S(A)
O.D
BCD
N-
250
406
362.0
38.1
12-25
300
483
431.8
47.6
12-25
350
533
476.3
50.8
12-28
400
597
539.8
57.2
16-28
450
635
577.9
57.2
16-32
600
813
749.3
69.9
20-35
750
984
914.4
79.4
28-35
800
1061
977.9
88.9
28-41
850
1111
1028.7
88.9
32-41
900
1168
1085.9
88.9
32-41
1100
1403
1314.5
117.5
40-41
BSS-0202-A
REMARK
ASME/ANSI
B16.47, 150#
series A.
A4(210X297)

FRP Fabrication Manual

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FRP Fabrication Manual

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One of the Leading Company for FRP PIPE & FITTINGS

Engineering & Manufacturing in the World

FRP PIPE & FITTINGS

BOSUNG ENGINEERING & MANUFACTURING Co.Ltd.

BOSUNG E.& M. STANDARD

This fabrication manual shall apply to the fabrication of F.R.P (Glassfiber

Glass Fiber Mat shall be kept under the humidity-free condition.

2.0 Application Code

Chemical Protective Resistance Layer + Structure

layer + U.V. Protection Layer

Chemical Protective Resistance Layer + Structure

layer + U.V. Protection Layer

Isophthalic Polyester Resin shall be used for resin.

Fillers, Accelerators or Catalysts

Before using accelerators or catalysts, users must take curing into

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

YARN Type "E" Glass

Top Coating (Including Ultraviolet Inhibitor)

Inner Surface Layer

Isophthalic Polyester Resin shall be used for this layer.

Inner Surface shall be free of cracks and crazing.

Between 0.01 inch and 0.02 inch of reinforced resin-rich surface

Surface must avoid exposure of inner surface fabric.

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

F.R.P. Piping Fabrication

Vinylester Polyester Resin shall be used for this layer.

Reinforcing Layer shall be lapped with Type "E" Glass YARN.

Pipe wall thickness can be controled by Reinforcing Layer.

Considering air bubbles, the layer shall be

lapped up to 0.12 ~ 0.16inch thickness and then cured.

Exterior Surface shall be lapped by the sufficient resin which

Considering the outer corrosive environment, the resin used for

Structural elements having cut edges exposed to the chemical

F.R.P pipe connecting must be conducted by Butt Joint or Flange Joint.

In principle, connecting pipe to pipe shall be done by Butt Joint.

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

F.R.P. Piping Fabrication

Butt Joint shall be applied in accordance with the followings :

The joint finish must be a successive layers' structure and the

The width of the first layer shall be a minimum of 2inch.

Successive layers shall increase uniformly to provide the specified

Over Lay TH'K(mm)

Outer Minimum Width(mm)

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

F.R.P. Piping Fabrication

Pipe Wall Thickness

F.R.P Standard Pipe wall thickness shall be in accordance with maker's

Isolated small spots of pipe may be as thin as 87.5% of the minimum

All fittings shall be the same as corresponding pipes in strength,

The face of the flange attachment shall be flat faced flange.

The perpendicular allowance of flange face shall be less than 1/2to

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

F.R.P. Piping Fabrication

PIPE DIMENSION TABLE

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD

F.R.P. Piping Fabrication

BOSUNG ENG. &MFG. CO., LTD.

BOSUNG E.& M. STANDARD